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Montalvo
Z4-UL
Unwind Tension Controller for Load Cell Feedback
|||||||||||||||||||||||||||
SERXXXXXX
MADE IN USA
SUPPLY
100-240 VAC
ONLY
(Fuse: 3.15A Slow Blow)
N
L
(COM)
24V
Z4-UL Unwind (for Load Cell feedback)
PID Web Tension Controller
Version 1.0 / Publication Date 2014-12-16
info@montalvo.com / www.montalvo.com /
TECHNICAL MANUAL
Run Mode TENOFF
Z4XXXX-X
100/240VAC 0.6A
R6
R5
R4
R3
R2
R1
Z4 CONTROLLER REV
(C) 2014 MONTALVO
PE
Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo
1947
.
EST
MAN / AUTO
TENSION
CAL
1
2
2
2
2
MODE
100.0
50.0
40.0
60.0
75.0
30.0
70.0
50.0
80.0
20.0
10.0
90.0
25.0
Tension
00.0
100.0
00.0
Output
Setpoint
DISPLAY
ADJUST
TREND
CONFIG
Circuit Board Version
AUTO
Setpoint
65.0
LB
Manual
42.0
PSI
Aux
62.7
%
Diameter
24.5
in
Enclosure Version
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Related Manuals for Montalvo Z4-UL
Summary of Contents for Montalvo Z4-UL
- Page 1 (Fuse: 3.15A Slow Blow) Z4 CONTROLLER REV (C) 2014 MONTALVO (COM) Z4-UL Unwind (for Load Cell feedback) PID Web Tension Controller Version 1.0 / Publication Date 2014-12-16 info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 2: Table Of Contents
Table of Contents 1 General Description ..................... 3 2 Mechanical Installation ..................6 Circuit Board (controller) Dimensions ..............6 HMI (remote interface) Dimensions ..............7 Enclosure Dimensions ..................8 3 Electrical Installation ................... 9 Warning, EMC, and Safety .................. 9 Basic Diagrams B Version (circuit board only) ............ - Page 3 Table of Contents 6 Operation of the Controller Menu .............57 Operation of the Controller Menu ..............57 Menu Tree [Status Menu] ..................58 Description [Run Mode] ..................58 Menu Tree [Setup Menu] ...................59 Menu Tree / Parameter Settings ................60 7 Hardware Adjustment and LEDs ...............65 LEDs .........................65 Potentiometers ....................65...
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Page 4: General Description
General Description Overview The Montalvo Z4 Unwind tension controller provides precise automatic control of web tension. The progressive PID regulator automatically compensates for roll diameter. The controller is used in a closed loop, of which the load cell roller and a brake (or other tension-affecting device) are part. - Page 5 USB to PC I/P Converter (Option) (Option) OUTPUT Automatic Range Expander (Option) Regulated Air (2, 3 or 4 lines - multiple torque ranges) Air Supply info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 6 Toggles between manual and auto mode. Tension On/Off Button Turns tension on and off. Output is zero when off. Yellow Power LED Indicates that power is on. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 7: Mechanical Installation
1.30 4.72 (177) (33) 6.97 (120) 2.64 (67) Avoid mounting the controller close to drive controllers or any other equipment producing large amounts of EMI. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 8: Hmi (Remote Interface) Dimensions
1.47 (38) 5.35 (136) 7.00 (178) 1.85 (47) 0.118 (3) max. radius Cut Out +0.020 -0.000 (193.04) +0.5 -0.0 +0.020 5.43 -0.000 (137.92) +0.5 -0.0 info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 9: Enclosure Dimensions
4.30 10.83 (275) (110) 1/4 Turn Compression Latch Avoid mounting the controller close to drive controllers or any other equipment producing large amounts of EMI. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 10: Electrical Installation
/ www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 11: Basic Diagrams B Version (Circuit Board Only)
(DI 1) (DI 3) converter uses (4-20mA) (0-10V) 24V power supply) I/P Converter Voltage (Current 4-20mA) 0-10V Tension Input Regulated Output Function Switches info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 12: Basic Diagrams R Version (Circuit Board With Remote Hmi)
(DI 1) (DI 3) converter uses (4-20mA) (0-10V) 24V power supply) I/P Converter Voltage (Current 4-20mA) 0-10V Tension Input Regulated Output Function Switches info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 13: Basic Diagrams E Version (Circuit Board And Hmi In Enclosure)
(DI 1) (DI 3) converter uses (4-20mA) (0-10V) 24V power supply) I/P Converter Voltage (Current 4-20mA) 0-10V Tension Input Regulated Output Function Switches info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 14: Terminal Blocks
Roll Pulse DI 7 DI 6 Web Pulse Run DI 5 DI 4 Cal 2 Tension Off DI 3 DI 2 Splice Manual DI 1 info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 15: Installation - Load Cell
Electrical Installation 3.6 Installation - Load Cell The following terminals are for load cell connections. The standard cable from Montalvo is supplied with a connector for the load cell. Wire the other end into the terminal block of the circuit board. -
Page 16: Installation - Tension Calibration
2. Before applying power to the controller, check that analog tension meter, if used, is set to Version Tension zero. If using Montalvo M4 tension meter, mechanically adjust needle with screw at base of Setpoint meter scale as needed. Note: If using Z4 HMI, digital display of tension will match circuit Output board adjustment. -
Page 17: Installation - Regulated Output
Z4 CONTROLLER REV2 (C) 2014 MONTALVO (COM) 0 to 10V B - I/P Converter Wiring 4 to 20mA (signal = 4 to 20mA and 24V supply) info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 18: Installation - Power Supply (Vac And Vdc)
PE Ground SERXXXXXX 24VDC 0.75A MADE IN USA SUPPLY 24 VDC ONLY (Fuse: 1.0A) Z4 CONTROLLER REV2 (C) 2014 MONTALVO (COM) N (COM) L (24V) info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 19: Digital Input (24V)
Diameter diameter calculation. Fast This input is used to control the regulator when DI 8 Yellow Stop Stop the machine is making a fast stop. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 20 The run signal is activated with a high (24V) signal. If the inverted function is needed, then change the parameter [DI-5 Invert] to [YES]. Default is set to [NO]. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 21 The stop signal is activated with a high (24V) signal. If the inverted function is needed, then change the parameter [DI-8 Invert] to [YES]. Default is set to [NO]. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 22: Digital Output (24V)
DO 1, DO 2, DO 3, DO 4 None *All DO outputs NOT used for range expender can be used for web break or diameter alarm. See 5.10 Digital Output Menu. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 23: Analog Input (0 To 10V)
0-10VDC input range. Aux1 Input 0 to 10V 0 to 10V Aux1 Input 0 to 10V Note: For parameter set-up, see 5.13 Aux1 Input. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 24 The signal on terminal 25 can be offset adjusted on R4. Span Adjustment (R5) (range: 1-50) The signal on terminal 25 can be span adjusted on R5. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 25: Analog Output (0 To 10V)
Aux 1 Output 0 to 10V Z4-BULANS ||||||||||||||||||||||||||| SERXXXXXX 100/240VAC 0.6A MADE IN USA SUPPLY 100-240 VAC ONLY (Fuse: 3.15A Slow Blow) Z4 CONTROLLER REV2 (C) 2014 MONTALVO (COM) info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 26: Voltage To Current Converter
Output from voltage to current converter. Converts 0 to 10V 4 to 20mA Output on terminal 58 into 4 to 20mA. 0V for analog signal. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 27: Tuning
Machine must be running at LOW speed to adjust. Not all menus appear all the time. Menus either irrelevant to the mode or without the correct password will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 28: Confi Guration And System Setup
Wrap angle Menu Com Menu Not all menus appear all the time. Menus either irrelevant to the mode or without the correct password will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 29: Options Selection Menu [Options Menu]
Requires discrete diameter reference. Please contact Montalvo for further details. [DI Mode Menu] Different modes for DI can be set up under this menu. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 30: Regulator Parameter [Regulator Menu]
The higher the value, the longer integral time within the PID regulator. D Level (range: 0-255) • Derivative gain level of the PID regulator. • The higher the value, the larger D-level within the PID regulator. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 31: Roll Change [Roll Change Menu]
2. To see the new output level after changing the [New Output] parameter, switch tension off and then on again. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 32 If Setup Menu Diameter Menu Dia Source = [Aux1], [Aux2] or [Aux3] , [New Roll D] will be set by selected Aux input value. • Set [New Roll D] for most common diameter used, as a percentage of maximum diameter. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 33: Starting The Machine [Start Menu]
= [Hold Level]. [Hold Level] = stored level + x% Hold Stop Hold Mode Mode Mode Mode 100% Machine Speed Hold Delay Time 100% Controller Output Time info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 34 Step 5 If adjustment in Step 4 has been made, return to Step 2. the time. Menus either irrelevant to the mode or without the correct password will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 35: Stopping The Machine [Stop Menu]
The level is set by the fast stop parameter. Typical set-up is [Source] = [OUTPUT]. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 36 Step 5 Decrease [F-Stop Min] if tension rises; increase [F-Stop Min] if tension drops. Step 6 If the adjustment has been made in Step 5, return to Step 2. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 37 Step 5 Decrease [F-Stop Max] if tension rises; increase [F-Stop Max] if tension drops. Step 6 If the adjustment has been made in Step 5, return to Step 2. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 38: Machine At Stop [Hold Menu]
Examples of the output level in [Hold Mode]: Hold Menu [Hold Level 100%] => Stored Level Hold Menu [Hold Level 150%] => Stored Level + 50% info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 39: Diameter [Diameter Menu]
(Note that value reverts to .0 but parameter has be accepted). [Dia Factor] now will now display a factor used for diameter calculations. • Scroll to: [Diameter] to verify actual diameter. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 40 The recommended web length/pulse is between 10 and 250 mm/pulse. • For better resolution, use a short distance between the pulses. • Note: The maximum input frequency must not exceed 15KHz. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 41 If the application does not require maximum diameter, the parameter can be adjusted. [New Roll D] parameter is located under the [Roll Change Menu]. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 42: Taper [Taper Menu]
Wrap Angle Menu Com Menu Not all menus appear all the time. Menus either irrelevant to the mode or without the correct password will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 43: Digital Output [Digital Output Menu]
[Wbr Time], output will be activated (i.e. go high). See illustration. Web break function is active Delay Machine Speed Time Tension Level Time Run/DI-5 Time Web break info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 44 When a diameter is beyond the level set up in this parameter, this will activate the digital output. Note: If the diameter is using [PULSE] as source, this is in mm. Otherwise the diameter is displayed in %. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 45: Splice [Splice Menu]
HMI of the enclosure version. The option should be used in cases where splice levels vary to a high degree. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 46 [Spl Delay], if required. Knife signal or splice button Splice / DI-2 Splice Splice Delay Time Splice Level Regulated Output Time Tension Setpoint Tension Time info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 47 Start the machine at slow speed. Note the output level when tension has stabilized. c) Adjust [Spl Level] to the output noted in step b). (Note: the output level is scaled with the setpoint.) info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 48 Paper (40g / 25 lb) 100% password will not appear. Paper (40g / 25 lb) Paper (40g / 25 lb) Paper (80g / 25 lb) 100% info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 49 Menus either irrelevant to the mode or without the correct password will not appear. Splice Time Splice Level Regulated Output Time Tension Setpoint Tension Time info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 50: Range Expander [Range Exp Menu]
In a standard braking system, each brake pad is connected in parallel to the regulated air output. Start Menu Stop Menu In a range expander system, pads are divided into groups called ranges using the Montalvo Hold Menu P3000HD-RE Automatic Range Expander. There can be between 2 and 4 ranges. Each range Diameter Menu is driven from a separate valve switch within the enclosure. - Page 51 Time password will not appear. Range Range Range Time Time Time Output Pressure Range 4-3 Range 3-2 Range 2-1 Time (133%) (150%) (200%) info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 52 3 I/P Converter, 0-6 Bar 4 Emergency Stop Valve 5 Manometer 6 Range 1 Valve 7 Range 2 Valve 8 Range 3 Valve 9 Range 4 Valve info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 53 If output level is over the [Up Level] and longer than [Range Time], the controller will switch up one range. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 54 [Brake Menu] irrelevant to the mode [2/1 Dia] or without the correct password will not appear. Note: This is only a read-out parameter. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 55: Aux1 Input [Aux1 Input Menu]
The Analog Input signal can be inverted with this parameter. NO 0 to 10V = 0.0 to 100.0%. YES 10 to 0V = 0.0 to 100.0%. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 56: Aux2 Input [Aux2 Input Menu]
The Analog Input signal can be inverted with this parameter. NO 0 to 10V = 0.0 to 100.0%. YES 10 to 0V = 0.0 to 100.0%. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 57: Aux1 Output [Aux1 Output Menu]
Please contact Montalvo for further details. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 58: Operation Of The Controller Menu
Press Enter ( ) ..........to edit the parameter (the cursor will blink) Press Up or Down [] ............until [80.0] appears in the display g) Press Enter ( ) ..................to store the change info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 59: Menu Tree Status Menu
Tension off is activated and the output level is set to zero. [STDBY] The output level is set to zero. [SPLICE] The splice signal (terminal 2) is activated and the controller is performing a splice. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 60: Menu Tree [Setup Menu]
[Aux1 Output Menu] Enter to edit analog auxiliary 1 output parameters. [Wrap Angle Menu] Enter to edit variable wrap angle parameters. [Com Menu] Enter to edit optional communications parameters. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 61: Menu Tree / Parameter Settings
0 to 255 Intel Int NO | YES NOTE: Not all menus appear all the time. Menus, irrelevant or without appropriate an password, will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... - Page 62 NONE | DO1 | DO2 | DO3 | DO4 NOTE: Not all menus appear all the time. Menus, irrelevant or without appropriate an password, will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 63 Shift Up Menu 1->2 0 to 200 NOTE: Not all menus appear all the time. Menus, irrelevant or without appropriate an password, will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 64 Cal 2 Menu (If Use Var Wrap = YES) -32767 to 32767 -32767 to 32767 NOTE: Not all menus appear all the time. Menus, irrelevant or without appropriate an password, will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
- Page 65 NO | YES DI-8 NO | YES Value Menu NOTE: Not all menus appear all the time. Menus, irrelevant or without appropriate an password, will not appear. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo...
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Page 66: Hardware Adjustment And Leds
Adjusts tension to show actual web tension. See 3.7 Range Installation – Tension Calibration. Zero Used to adjust zero of tension. See 3.7 Installation – Tension Range Calibration. info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 67: Troubleshooting
Troubleshooting 8.1 Block Diagram info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 68: Symptoms / Causes
Room 1103, Block 11, East YunLing www.montalvo.cn Road 599#, PuTuo District Shanghai, China 200062 Applications Hot-Line Tel: +86-21-52188010 24/7/365 in USA and Canada Fax: +86-21-52188020 1-800-226-8710 info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 69: Technical Data
14 to 176° F (-10 to 80° C) Degree of Protection - Enclosure IP54 Degree of Protection - Circuit Board IP10 Degree of Protection - HMI IP65 info@montalvo.com / www.montalvo.com / Technical details subject to change without notice. Z4-UL-technical manual-us © Montalvo... -
Page 70: Communication
(COM) COMMUNICATION (USB 2.0 Option) The Montalvo Z4 controller is available with an optional USB communications port for setting up and viewing the status of parameters by a computer. All items necessary for using USB are included in the package. -
Page 71: Ethernet (Option)
COMMUNICATION Ethernet Option (e.g. Ethernet/IP) The Montalvo Z4 Controller will soon be available to provide communication capability within an industrial ethernet network (e.g. Ethernet/IP). This option can be added to an existing Z4 board by simply swaping out the ethernet capable communications card with the existing card. - Page 73 D-30539 Hannover Germany Tel: +49 (0)511 760 691 41 info.de@montalvo.com 1947 The Montalvo Corporation 50 Hutcherson Drive, Gorham, Maine 04038 USA Fax: 1-800-644-5097 / 207-856-2509 1-800-226-8710 / info@montalvo.com / www.montalvo.com Technical details subject to change without notice. Z4UL-technical manual-us © Montalvo...
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